Mold and core arrangement for casting hollow elongated bodies



Sept. 21, 1965 BELLSNYDER, JR 3,206,811

MOLD AND CORE ARRANGEMENT FOR CASTING HOLLOW ELONGATED BODIES Filed Dec. 26, 1962 3 Sheets-Sheet l INVENTOR. Thomas BeHsr ya Q Jr:

Hikormys p 21, 1965 T. BELLSNYDER, JR

MOLD AND CORE ARRANGEM ENT FOR CASTING HOLLOW ELONGATED BODIES 3 Sheets-Sheet '2 Filed Dec. 26, 1962 Ill/I'll I 1 INVENTOR. Thamas Bel/sn de; Jr:

Sept. 21, 1965 T. BELLSNYDER, JR

MOLD AND CORE ARRANGEMENT FOR CASTING HOLLOW ELONGATED BODIES Filed Dec. 26, 1962 3 Sheets-Sheet 3 INVENTOR Th oma.s Bells ngder, Jr.

Httorneus United States Patent 3,206,811 MOLD AND CORE ARRANGEMENT FOR CASTING HOLLOW ELONGATED BODIES Thomas Bellsnyder, J12, 5412 9th Ave. 5., Birmingham, Ala. Filed Dec. 26, 1962, $22". No. 247,087 4 Claims. (Cl. 22184) This invention relates to a process and to a mold and core arrangement for casting hollow elongated bodies, for example, ingot molds.

In the art to which my invention relates it has heretofore been customary to cast hollow bodies such as ingot molds by standing the assembled mold with the core therein in upright position. The molten metal has been poured into the cavity from the top. Oftentimes, the pressure and the washing or eroding action of the cascading molten metal is sufficient to damage the core, thus forming an imperfection in the interior of the ingot mold being cast, making the casting unuseable. Further, the cores for such molds have been supported at the end adjacent the bottom of the ingot mold being cast by means of a metal pin projecting from the end of the core arbor into an adjacent wall defining the end of the mold cavity. Heretofore if the pin has been large enough not to melt prematurely upon pouring the casting it often has happened that the metal of the casting adjacent the pin has been excessively chilled, and if the diameter of the pin was reduced enough to prevent chilling, the pin has burned in two, permitting the core to shift.

The prime object of my invention is to overcome the above objections and to provide a casting process in which the assembled mold-core combination is supported with one end raised above the other, that is with the longitudinal axis of the mold at an angle to the horizontal. The upper end of the cavity is provided with a riser and the cavity is filled by pouring the molten metal into the lower end of the cavity. The metal thus rises gradually around the core, eliminating the washing and eroding effect thereon and reducing the ferrostatic pressure on the core.

Another object is to provide apparatus of the character designated in which the diameter of the core supporting pin is reduced to prevent chilling of the casting being made, and the mass of at least a portion of the exposed end of the metal pin supporting the end of the core is increased, thus to prevent premature melting of the pin.

A further object is to provide a mold-core combination which is effective to carry out my improved process and which embodies the structural improvements mentioned herein.

Apparatus illustrating the constructional features of my invention and which also is capable of carrying out my improved process is shown in the accompanying drawings in which:

FIG. 1 is a side elevational view of assembled cope and drag mold sections with my improved core in place therein, partly broken away and in section;

FIG. 2 is a plan view of the assembled mold shown in FIG. 1;

FIG. 3 is a detail sectional 33 of FIG. 2;

FIG. 4 is a view of the cope section of the mold removed from the drag and showing the cavity formed therein with the patterns withdrawn;

FIG. 5 is a plan view of the drag with the cope removed and showing my improved core in place therein;

FIG. 6 is a view of the finished ingot mold prior to removing the core therefrom;

FIG. 7 is a detail fragmental sectional view drawn to an enlarged scale and showing one means for increasing view generally along line 326,811 Patented Sept. 21, 1965 the mass of the portion of the exposed end of the core supporting pin;

FIG. 8 is a side elevational view of a preferred form of protective sleeve for the pin; and,

FIG. 9 is an end elevational view of the sleeve shown in FIG. 8.

Referring now to the drawings for a better understanding of my invention I show in FIG. 1 the cope section 10 and the drag section 11 of an assembled mold and core arrangement embodying my invention. The cope is provided with a riser 12 and a pouring basin 13. It is to be especially noted that the riser end of the mold is supported above the level of the end on which the pouring basin is placed. This may conveniently be done by means of a bottom board 14. Preferably, the angle of the longitudinal axis of the cavity relative to the horizontal is on the order of 5 to 20, 15 being the preferred inclination. The metal poured into the pouring basin runs downwardly through suitable openings 16 in the sand of the cope and finally through the passages 17 enters the lower end of the cavity 18 of the mold. Thus, and as will appear more fully hereafter, the metal rises gradually from the lower end of the cavity to the upper end, it being noted that the riser is slightly below the level of the metal in the pouring basin so that the operator con discern when the cavity is filled. It will of course be understood that the cope and drag sections are sandfilled and that the cavity is formed by suitable patterns, not shown, thus making the cavity conform to the: outer configuration and dimensions of the article to be cast, such for in stance, as an ingot mold shown at M in FIG. 6.

It will be understood that prior to pouring the core 19 is put in place thus to form the inner cavity of the ingot mold to be cast. As stated, it is customary to produce the core 19 by molding sand around a tubular, perforated core arbor 21 which runs substantially all the way through the core. In the instance shown the arbor 21 projects from the lower end of the mold as at 20 serving to vent the core. The upper end of the arbor is provided with a short length of rod 21" which projects into and may be supported by the two parts 22 and 23 of a chill, core, or a core print. As shown particularly in FIG. 7 it will be seen that the rod 21 is reduced in diameter over the diameter of the arbor and may be scored as at 21 to weaken the pin near the end of the core which is to form the bottom of the ingot mold. The purpose of this is to permit the pin to be broken off, after the sand of the core is removed when the casting M is withdrawn from the mold. This feature is disclosed in Bellsnyder Patent 2,419,873 date April 29, 1947. After the casting M is withdrawn from the mold the outer projecting end of the pin is removed.

In order to prevent the reduced pin portion 21 from premature melting thus to permit shifting of the core during pouring, I increase the mass of at least a length of the portion of the pin which is to be subjected to the hot molten metal. Preferably, I place around the pin 21 a sleeve 24. Also, I preferably provide the sleeve 24 with a plurality of holes 26 therein so that the molten iron may readily run into and surround the pin. It will further be noted that the sleeve 24 is placed on the pin between the adjacent end of the core and the chill 2223, core, or core print as the case may be so that upon completion of the casting the sleeve 24 itself becomes embedded into and becomes an integral part of the outside bottom of the ingot mold being cast. That is, the sleeve is placed away from the inner bottom or casting surface of the ingot mold being cast so that the pouring surface of the finished mold is not chilled.

From the foregoing the method of carrying out my improved process and the constructional features of my invention as well as the advantages thereof may now be explained and readily understood. With the core assembled in the mold, and with the sleeve 24 in place, and the mold elevated on the bottom board as illustrated so that the riser is at the highest point, molten metal such as cast iron is poured into the pouring basin 13. The metal enters the cavity at the lower end, rising gradually to the upper end which in the instance shown is the bot tom of the ingot mold being cast. Due to the gradual rising of the metal I have been enabled to reduce substantially the amount of eroding action on the core. When the metal reaches the upper end of the mold it flows gradually around the exposed part of the pin 21* and covering and filling the sleeve 24. The mass of the metal forming the sleeve 24 is sufficient to prevent the pin from melting prior to solidification of the casting being made. However, being located away from the inner bottom of the ingot mold being cast, the pouring surface of the ingot mold is not chilled. I thus assure that the core is not eroded and that it remains perfectly centered until the casting has solidified to the extent necessary to prevent movement of the core.

My improved process and apparatus has been used and is being used commercially in the making of ingot molds in the smaller sizes. My improved process and apparatus is extremely satisfactory and in fact has reduced by about some 20 to 25 percent the number of rejects in the finished cast ingot molds. By using the sleeve or other means to increase the mass of exposed pin 21 I am enabled to use a smaller pin, thus to reduce chill in the bottom of the ingot mold being cast. It will be noted that when completed the sleeve lies at the outside of the bottom of the ingot mold. Thus, the casting surface of the bottom of the mold is unchilled, and yet, due to the sleeve, the pin is prevented from premature melting. The grain structure of the pouring surface of the bottom of the finished mold thus is substantially that of the side Wall of the mold, eliminating scaling and flaking and consequent contamination of ingots poured in such molds.

While I have shown and particularly described my invention as applicable to casting closed bottom ingot molds, the feature hereof relating to pouring on an incline is useful for making castings open at both ends, such for instance as open bottom ingot molds.

While I have shown my invention in but one form, it will be obvious to those skilled in the art that it is not so limited but is susceptible of various changes and modifications without departing from the spirit thereof, and I desire, therefore, that only such limitations shall be placed thereupon as are specifically set forth in the appended claims.

What I claim is:

1. A ready-to-pour mold and core combination for casting elongated hollow bodies comprising:

(a) a two-part sand-lined mold having a cavity therein corresponding to the outer configuration of the elongated hollow body to be cast,

(b) a core supported at one end in the cavity by a metal pin projecting from the end of the core into of the pin exposed to the metal to be poured into the cavity,

(c) a body of metal formed entirely separately from the pin carried by a portion of the exposed part of the pin and of a size to protect the exposed portion of the pin and of a size to protect the exposed portion of the pin against premature melting,

(d) means to fill the cavity with molten metal from the end thereof opposite the exposed portion of the pin, and

(e) and a riser in communication with the cavity adjacent the end thereof containing the exposed portion of the pin.

2. The mold of claim 1 in which the body of metal carried by the pin is in the form of a sleeve, there being a plurality of openings through the side walls of the sleeve.

3. The mold of claim 1 in which the body of metal carried by the supporting pin is located at a point along the pin removed from the adjacent inner wall of the casting being made.

4. The mold of claim 1 in which the body of metal carrid by the pin is in the form of a sleeve, there being a plurality of openings through the side walls of the sleeve, and said sleeve being located in the cavity in such position that when the casting is poured, the sleeve becomes a part of the casting being made.

References Cited by the Examiner UNITED STATES PATENTS 974,218 11/10 Wells 22184 1,256,588 2/ 18 Nilsson 22-91 1,327,689 1/20 Waitt 22-484 1,591,423 7/26 Hunt 22-184 1,924,280 8/33 Hobart 22184 2,419,873 4/47 Bellsynder et a1. 22-433 4 FOREIGN PATENTS 831,636 6/38 France.

WILLIAM J. STEPHENSON, Primary Examiner.

MARCUS U. LYONS, Examiner. 

1. A READY-TO-POUR MOLD AND CORE COMBINATION FOR CASTING ELONGATED HOLLOW BODIES COMPRISING: (A) A TWO-PART SAND-LINED MOLD HAVING A CAVITY THEREIN CORRESPONDING TO THE OUTER CONFIGURATION OF THE ELONGATED HOLLOW BODY TO BE CAST, (B) A CORE SUPPORTED AT ONE END IN THE CAVITY BY A METAL PIN PROJECTING FROM THE END OF THE CORE INTO OF THE PIN EXPOSED TO THE METAL TO BE POURED INTO THE CAVITY, (C) A BODY OF METAL FORMED ENTIRELY SEPARATELY FROM THE PIN CARRIED BY A PORTIN OF THE EXPOSED PART OF THE PIN AND OF A SIZE TO PROTECT THE EXPOSED PORTION OF THE PIN AND OF A SIZE TO PROTECT THE EXPOSED PORTION OF THE PIN AGAINST PREMATURE MELTING, (D) MEANS TO FILL THE CAVITY WITH MOLTN METAL FROM THE END THEREOF OPPOSITE THE EXPOSED PORTION OF THE PIN, AND (E) AND A RISER IN COMMUNICATION WITH THE CAVITY ADJACENT THE END THEREOF CONTAINING THE EXPOSED PORTION OF THE PIN. 